air cooler maintenance
Post on 20-Jan-2016
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2
“AIR COOLER” Heat ExchangerGeneral Assembly view
Structure
Stationary Header
Floating Header
Plug
Tubes
Electric motor
Fan
Conveyor
Inlet
Outlet
Scaffold
3
“AIR COOLER” Heat Exchanger
Tube Bundle DetailsVapor Inlet
Condensate Outlet
Stationary Header
Fin Tubes
Floating Header
Plug
4
“AIR COOLER” Heat Exchanger
Tube Assembly and Plug Detail
Stationary Header
Fin Tubes
Plug
Gasket
Inlet
Grooves for expansion
5
“AIR COOLER” Heat Exchanger
Maintenance Activity Cases Summary
1. Leakage from Header Plugs
2. Leakage from Tubes
1.1. On Line leak elimination [Temporary solution]
2.1. Leak elimination from expanded area
2.2. Leak elimination from broken tube
2.3. On line Leak elimination from broken tube
[Temporary solution, Bottom & Top row only]
6
Do Not Start The Job Without a Safety Plan
7
“AIR COOLER” Heat Exchanger1. Leakage from Header Plugs
1.1. On Line leak elimination [Temporary solution]
Drill blind hole and thread the leaking Plug on situ
Assembly the special cap device with gasket and screw it in until the leak stops
This is a Maintenance Innovation made by IZ
Leaking Plug
Screw in the threaded stud
Inlet Header
Fin Tubes
Replace gasket & Plug later in Shutdown
Special device
Leak
Additional Gasket
8
“AIR COOLER” Heat Exchanger2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
Shutdown, isolate & drain the equipment
Stationary Header
Fin Tube
Blind Stationary Header Inlet & Outlet
Install Pressure Gauge
Connect water pump
Fill system by water
Locate leaks from outside
Raise the pressure
Open Plugs at leak position
Remove gasket
Plug
Water Pump
PG
Leak
See continuation
Discharge water
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“AIR COOLER” Heat Exchanger2. Leakage from Tubes: Insert Expander tool, expand the tube up
to the established torque
Stationary Header
Fin Tube
Remove expander tool
Reinstall new gasket and plug
Fill the system by water
Re-check leaks from outside [No more leak]
Raise the pressure
Discharge water
Remove PG & water pump
Plug
Water Pump
PG
Leak
Remove In-Out Blinds and tight flange bolts
2.1. Leak elimination from Tube Expanded Area
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“AIR COOLER” Heat Exchanger2. Leakage from Tubes:
Stationary Header
Fin Tube
Plug
Water Pump
Leak
Shutdown, isolate & drain the equipment
Blind Stationary Header Inlet & Outlet
Install Pressure Gauge
Connect water pump
Fill system by water
Locate leaks from outside
Raise the pressure
Open Plugs at leak position both sides And remove gasket
Plug the leaking tube [both sides]
Fill in water again
Raise pressure & check sealing
Drain water, remove PG & pump
Remove in-out blinds, tight bolts
Remove field blinds
2.2. Leak elimination from broken Tube
Drain water
Reinstall gasket & plugs [Both sides]
PG
11
“AIR COOLER” Heat Exchanger2.3. On line Leak elimination from broken tube : [Temporary solution]
[Bottom & Top row only]
Drain Valve
Section “B-B” Section “C-C”
Leak
B
B
C
C
Special Device
See continuation
12
“AIR COOLER” Heat Exchanger2.3. On line Leak elimination:
Steam
Condensate
DEVICE INSTALLATION METHOD
Leak
from broken tube : [Temporary solution]
[Bottom & Top row only]Stop the fan set only
Remove fins at leaking areaInstall the upper half body with gasket
Install the lower half body with the drain open
Tight the body bolts
Install packing and gland at left side and tight bolts
Install packing and gland at right side and tight bolts
Close the drain
Erect scaffold below fan
13
“AIR COOLER” Heat Exchanger
Handover & Final House Keeping
Close Work permit
Remove tools and equipment
Clean and wash the area
Remove scaffold before El. Fan start-up
By Maintenance
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